Dual-direction chemical delivery system for ALD/CVD chambers

ABSTRACT

Provided are gas distribution apparatus with a delivery channel having an inlet end, an outlet end and a plurality of apertures spaced along the length. The inlet end is connectable to an inlet gas source and the outlet end is connectible with a vacuum source. Also provided are gas distribution apparatus with spiral delivery channels, intertwined spiral delivery channels, splitting delivery channels, merging delivery channels and shaped delivery channels in which an inlet end and outlet end are configured for rapid exchange of gas within the delivery channels.

BACKGROUND

Embodiments of the invention generally relate to an apparatus and amethod for flowing a gas into a processing chamber. More specifically,embodiments of the invention are directed to dual directional chemicaldelivery systems.

In the field of semiconductor processing, flat-panel display processingor other electronic device processing, vapor deposition processes haveplayed an important role in depositing materials on substrates. As thegeometries of electronic devices continue to shrink and the density ofdevices continues to increase, the size and aspect ratio of the featuresare becoming more aggressive, e.g., feature sizes of 0.07 μm and aspectratios of 10 or greater. Accordingly, conformal deposition of materialsto form these devices is becoming increasingly important.

With the ever-increasing requirements to achieve better depositionuniformity, high productivity and low defects in atomic layer depositionand chemical vapor deposition, many chemical delivery systems have beenproposed in the industry. More specifically, multi-channel systems withpump-purge capability have started to emerge in the industry due totheir unique properties. The multi-channel design avoids chemical mixingbefore introduction to the chamber. Integrated direct pump-purgecapability allows fast pumping of the channel, thus enabling higherproductivity and lower defects.

However, one of the biggest challenges facing the multi-channel directpump-purge system is the flexibility to tune deposition uniformity. Dueto the long channel length, the locations where the chemical and/orpurge are introduced will leave certain memory impact on the depositionuniformity. Furthermore, for the same hardware apparatus, differentmemory effects for different chemicals due to the differences in flowcharacteristics. For example, in a spiral channel design, the precursorabsorption flux on the wafer shows concentration gradient correspondingto the channel length. Accordingly, there is a need in the art forshowerhead designs to achieve better uniformity of precursordistribution.

SUMMARY

One or more embodiments of the invention are directed to gasdistribution apparatus to control flow of gas into a process chamber.The apparatus comprises a gas distribution plate having a front side andbackside. A gas delivery channel extends through the gas distributionplate and has a length which is defined by a first end and a second end.The delivery channel includes a plurality of apertures spaced along alength of the gas delivery channel. The apertures extend through the gasdistribution plate to the front side of the gas distribution plate. Agas delivery system is connected to the first end and the second of thegas delivery channel. The gas delivery system comprises a first inletline in flow communication with the first end of the delivery channeland a second inlet line in flow communication with the second end of thedelivery channel. The gas delivery system further comprises a pump line,a first purge line in flow communication with the first inlet line and asecond purge line in flow communication with the second inlet line. Theapparatus includes a controller to regulate the flow of gas through thedelivery channel and into the process chamber.

Additional embodiments of the invention are directed to the gasdistribution apparatus to control flow of gas until process chambercomprising a gas distribution plate with a first gas delivery channeland a second gas delivery channel. The gas distribution plate has afront side and backside. The first gas delivery channel extends throughthe gas distribution plate and has a length defined by first end of thesecond end.the first delivery channel includes a plurality of aperturesspaced along a length which extend through the gas distribution plate tothe front side of the gas distribution plate. The second gas deliverychannel extends through the gas distribution plate and has a lengthdefined by a third end and a fourth end.the second gas delivery channelincludes a plurality of apertures spaced along a length extendingthrough the gas distribution plate to the front side of the gasdistribution plate. the gas distribution apparatus includes a gasdelivery system comprising a first inlet line, a second inlet line, athird inlet line, a stop listening him fourth inlet line, a pump line, afirst purge line, a second purge line, a third purge line and a fourthpurge line. The first purge line is in flow communication with the firstend of the first gas delivery channel and the second inlet line is inflow communication with the second and of the first gas deliverychannel. The third inlet line is in flow communication with third end ofthe second gas delivery channel and the fourth inlet line is in flowcommunication with the fourth end of the second gas delivery channel.The first purge gas line is in flow communication with the first inletline, the second purge gas line is in flow communication with the secondinlet line, the third purge gas line is in flow communication with thethird inlet line and the fourth purge line is in flow communication withthe fourth inlet line. The apparatus includes a controller to regulatethe flow of gas through the first gas delivery channel and the secondgas delivery channel and into the process chamber.

Further embodiments of the invention are directed to processing chamberscomprising at least one gas distribution apparatus. Each gasdistribution apparatus comprises a gas distribution plate having a frontside and backside. A gas delivery channel extends through the gasdistribution plate and has a length which is defined by a first end anda second end. The delivery channel includes a plurality of aperturesspaced along a length of the gas delivery channel. The apertures extendthrough the gas distribution plate to the front side of the gasdistribution plate. A gas delivery system is connected to the first endand the second of the gas delivery channel. The gas delivery systemcomprises a first inlet line in flow communication with the first end ofthe delivery channel and a second inlet line in flow communication withthe second end of the delivery channel. The gas delivery system furthercomprises a pump line, a first purge line in flow communication with thefirst inlet line and a second purge line in flow communication with thesecond inlet line. The apparatus includes a controller to regulate theflow of gas through the delivery channel and into the process chamber.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the above recited features of the inventionare attained and can be understood in detail, a more particulardescription of the invention, briefly summarized above, may be had byreference to the embodiments thereof which are illustrated in theappended drawings. It is to be noted, however, that the appendeddrawings illustrate only typical embodiments of this invention and aretherefore not to be considered limiting of its scope, for the inventionmay admit to other equally effective embodiments.

FIG. 1 shows a gas delivery system in accordance with one or moreembodiments of the invention;

FIG. 2 shows a gas delivery system in accordance with one or moreembodiments of the invention;

FIG. 3 shows a view of a gas distribution apparatus in accordance withone or more embodiments of the invention;

FIG. 4 shows a view of a gas distribution apparatus in accordance withone or more embodiments of the invention;

FIG. 5 shows a top view of a gas distribution apparatus in accordancewith one or more embodiments of the invention;

FIG. 6 shows a cross-section of a perspective view of a gas distributionapparatus in accordance with one or more embodiments of the invention

FIG. 7 shows a perspective view of a gas distribution apparatus inaccordance with one or more embodiments of the invention;

FIG. 8 shows a bottom view of a gas distribution apparatus in accordancewith one or more embodiments of the invention;

FIG. 9A shows a partial cross-sectional view of a gas distributionapparatus in accordance with one or more embodiments of the invention;

FIGS. 9B through 9G show partial cross-sectional views of a gas deliverychannel and apertures in accordance with one or more embodiments of theinvention;

FIG. 10 shows a top view of a gas distribution apparatus in accordancewith one or more embodiments of the invention;

FIG. 11A shows a partial cross-sectional view of a gas distributionapparatus in accordance with one or more embodiments of the invention;

FIGS. 11B and 11C show partial cross-sectional views of gas deliverychannels and apertures in accordance with one or more embodiments of theinvention;

FIG. 11D shows the surface of a portion of the gas distribution plate ofFIG. 10C;

FIG. 12 shows a view of an exploded partial cross-sectional view of agas distribution apparatus in accordance with one or more embodiments ofthe invention

FIG. 13 shows a cross-section of a perspective view of a gasdistribution apparatus in accordance with one or more embodiments of theinvention

FIG. 14 shows a perspective view of a gas distribution apparatus inaccordance with one or more embodiments of the invention;

FIG. 15 shows a bottom view of a gas distribution apparatus inaccordance with one or more embodiments of the invention;

FIG. 16 shows a perspective view of a gas distribution apparatus inaccordance with one or more embodiments of the invention;

FIG. 17 shows a partial cross-sectional view of a gas distributionapparatus in accordance with one or more embodiments of the invention;

FIG. 18 shows a gas distribution apparatus in accordance with one ormore embodiments of the invention;

FIG. 19A a partial showerhead assembly in accordance with one or moreembodiment of the invention;

FIG. 19B shows an expanded view of a portion of the showerhead assemblyof FIG. 19A;

FIG. 20 shows a showerhead assembly in accordance with the embodiment ofFIG. 19A with multiple inlets and outlets; and

FIG. 21 shows another showerhead assembly in accordance with theembodiment of FIG. 19A with multiple inlets and outlets;

DETAILED DESCRIPTION

Embodiments of the invention are directed to gas distribution apparatusfor use in chemical vapor deposition and atomic layer deposition typeprocesses. The gas distribution apparatus described may be referred toas a showerhead or gas distribution plate, but it will be recognized bythose skilled in the art that the apparatus does not need to be shapedlike a showerhead or plate. The terms “showerhead” and “plate” shouldnot be taken as limiting the scope of the invention.

The inventors have found that a dual direction chemical delivery systemcan solve the channel concentration distribution induced non-uniformityissues. For example, in a spiral flow channel, when the precursor isintroduced from the center of a channel, it has higher concentration atcenter than at edge. The inventors have found that adding the capabilityto enable dual direction chemical delivery from either center or edge ofthe spiral can help to compensate for the non-uniformity inconcentration distribution.

In another example, when a precursor is introduced into a quadra-spiralchannel (see FIG. 20) from 0/90 degree and pumped from 45 degree, thedeposition map shows thinner deposition from center to 0/90 directions,leaving thicker deposition at four 45 degree sessions. Conversely, whenprecursor is introduced from 45 degree and pumped from 0/90 degree, thedeposition map shows thinner deposition from four 45 degree sessions,leaving thicker deposition at center to 0/90 directions.

Because of the complementary profile from those two configurations, adual direction chemical delivery system can take advantage of theconcentration distribution with the same hardware configuration. In bothchannel 1 and channel 2, the described embodiments enable dual directionchemical delivery in the same hardware set up. This not only conservesthe benefits of multi-channel set-up, but also incorporates theflexibility of modulation of chemical concentration distribution withoutcomplex re-design of other hardware components.

For example, the precursor delivery line can alternate from bothdirections to take advantage of the complimentary concentration profile.Embodiments can also alternate the purge flow in both directions. Thedeposition profile not only depends on the precursor flow, but also onthe purge flow. In ALD process, the purpose of the purge flow is toremove the residue chemicals in channel, chamber, and wafer surface.Similar to the non-uniform precursor delivery onto the wafer surface,purge flow can also have non-uniform purging effect on wafer surface,contributing to the non-uniformity in final deposition profile.

In some embodiments, both precursor flow and purge flow can be alternatedirections concurrently. The set-up can independently control flowdirections in an individual channel. The same set-up can alsoaccommodate alternating pumping directions with two additional valvesconnecting one of the inlets to the pumping lines.

Referring to FIG. 1, a first embodiment of the invention is directed toa gas distribution apparatus to control a flow of gas, or flows ofgases, into and out of a processing chamber. The gas distributionapparatus includes a gas distribution plate 400 which has a front side401 and a back side 403 and a gas. The front side 401 shown in theFigures faces a surface which processing is performed on, for example, asubstrate or a film on a substrate surface.

The gas distribution plate 20 includes at least one gas delivery channel(shown in FIGS. 3-21) which has a first end 404 and a second end 406.The terms “first end”, “second end”, “third end”, “fourth end” and thelike are used merely to designate an end of a gas delivery channel andare not intended to imply an order of operation or importance. Forexample, a channel that has two ends, has a first end and a second endeven though both are equivalent in nature.

A gas delivery system 10 is in flow communication, also called fluidcommunication, with the gas delivery channel. The gas delivery system 10has an inlet line 20 in fluid communication with the first end 404 andsecond end 406 of the gas delivery channel. The inlet line 20 shown inFIG. 1 splits into two legs making a first inlet line 21 which is inflow communication with the first end 404 and a second inlet line 22which is in flow communication with the second end 406 of the gasdelivery channel. Again, the naming/numbering of the inlet lines isarbitrary and should not imply order or preference.

A processing gas, also referred to as a reactive gas, flows through theinlet line 20 into the processing chamber through the gas distributionplate 400. The inlet line 20 shown includes an inlet wye 23 whichseparates the gas flow in the inlet line 20, thereby splitting the flowinto the first inlet line 21 and the second inlet line 22. The flowsplit through the wye 23 can be adjusted so 0-100% of the gas flowingthrough the inlet line 20 is directed down the first inlet line 21 withthe remainder (if any) directed through the second inlet line 22.

The inlet line 20 can include an inlet valve 24 in flow communicationwith the inlet line 20. The inlet valve 24 shown in FIG. 1 is locatedupstream of the inlet wye 23 and can be used to prevent any gas fromflowing through the inlet line toward the wye 23. As used in thisspecification and the appended claims, the terms “upstream” and“downstream” mean, respectively, before and after relative to thedescribed component. For example, the inlet valve 24 is upstream of thewye 23 means that a flow of gas would encounter the inlet valve 24before the wye 23.

The embodiment shown in FIG. 1 also includes a first inlet valve 25 inflow communication with the first inlet line 21 and a second inlet valve26 in flow communication with the second inlet line 22. Any or all ofthese valves, 24, 25, 26 an be fully open, fully closed or anywhere inbetween. The valves 24, 25, 26 can be operated manually orautomatically, and independently or together.

The gas delivery system 10 includes a purge line 30 which is used toflow a purge gas (e.g., an inert gas) into the processing chamberthrough the gas distribution plate 400 and through any of the lines influid communication with the purge line 30. The purge line 30 shown inFIG. 1 splits at a purge wye 33 into a first purge line 31 and a secondpurge line 32. The flow split through the purge wye 33 can be adjustedso 0-100% of the gas flowing through the purge line 30 is directed downthe first purge line 31 with the remainder (if any) directed through thesecond purge line 32.

The purge line 30 can include a purge valve 34 in flow communicationwith the purge line 30. The purge valve 34 shown in FIG. 1 is locatedupstream of the purge wye 33 and can be used to prevent any gas fromflowing through the purge line toward the wye 33. The embodiment shownin FIG. 1 also includes a first purge valve 35 in flow communicationwith the first purge line 31 and a second purge valve 36 in flowcommunication with the second purge line 32. Any or all of these valves,34, 35, 36 an be fully open, fully closed or anywhere in between. Thevalves 34, 35, 36 can be operated manually or automatically, andindependently or together.

In some embodiments, the first purge line 31 connects with and is inflow communication with the first inlet line 21 upstream of the gasdistribution plate 400 and the second purge line 32 connects with and isin flow communication with the second inlet line 22 upstream of the gasdistribution plate 400. The flow of purge gas to the processing chambercan be intermittent, pulsed or constant depending on the processingconditions. In some embodiments, a constant flow of a purge gas ismaintained so that the purge gas and reactive gases are flowingsimultaneously through the last portion of the inlet lines to the gasdistribution plate.

A pump line 40 is in flow communication with the gas distribution plate400 and connects to a vacuum system. The vacuum system can be anysuitable vacuum system including an individual vacuum pump or a houseforeline. In some embodiments, the pump line 40 is in flow communicationwith one or more of the first inlet line 21 and the second inlet line22. This configuration is shown on the left side of FIG. 2 but it willbe understood by those skilled in the bridging of the inlet lines andthe pump line can be included on any, all or none of the inlet lines. Apump valve 41 can positioned along the pump line 40 to isolate theprocessing chamber from the pump line.

A bypass line 50 can extend between the pump line 40 and the inlet line20 to draw reactive gases out of the system during purging of the lines.The bypass line 50 can include a bypass valve 51 to isolate the inlet 20from the pump line 40.

FIG. 2 shows another embodiment of the invention in which there are twoseparate gas delivery channels extending through the gas distributionplate 400. For clarity sake, valves have been left out of this drawing,but it will be understood by those skilled in the art, that any numberof valves can be placed along the various gas lines. For example, thevalves shown in FIG. 1 can have corresponding locations within thevarious gas lines of FIG. 2. Various dual channel embodiments aredescribed further below. The gas distribution plate 400 can have anynumber of individual gas delivery channels with any number of reactivegases. The embodiment shown in FIG. 2 has two gas delivery channels,with each channel delivering a different reactive gas A or B.

The first gas delivery channel has a first end 404 a and a second end406 a connected to, respectively, a first inlet line 21 a and a secondinlet line 22 a as in the embodiment of FIG. 1. The second gas deliverychannel has a third end 404 b and a fourth end 406 b. The third end 404b is in fluid communication with a third inlet line 21 b and the fourthend 406 b is in fluid communication with a fourth inlet line 22 b.

A purge line 30 a, 30 b is in fluid communication with the processingchamber through the first inlet line 21 a, second inlet line 22 a, thirdinlet line 21 b and fourth inlet line 22 b, as described above withrespect to FIG. 1. The embodiment shown has two purge lines 30 a, 30 bbut it will be understood that a single purge line can be used and splitusing a suitable splitting device (e.g., a gradient proportioning valve)into the various purge gas lines as needed.

In use, A reactant gas can be flowed through inlet line 20 towards theprocessing chamber. The gas flow in inlet line 20 can be split into afirst inlet line 21 and the second inlet line 22 at wye 23. The wye 23can be any suitable component which is capable of splitting the gasflow. For example, a gradient proportioning valve which is capable ofsplitting the flow within a range of 100:0 into first inlet line21:second inlet line 22 to 0:100 into first inlet line 21:second inletline 22. In one or more embodiment the Wye 23 splits the gas flow aboutevenly between the first inlet e 21 and the second inlet line 22. Withan even split between the inlet lines, assuming all else is equal, thepressure of the reactive gas at the first end and second and of the gasdelivery channel will be even.

A purge gas, which can be any suitable gas such as an inert gas or adiluent gas, can be flowed through purge line 30. The purge gas flow canbe split at wye 33 into a first purge line 31 and the second purge line32. The first purge line 31 and second purge line 32 can flow directlyinto the processing chamber or, as shown in the figures, can merge withthe first inlet line 21 and second Inlet line 22. The flow of purge gasentering the inlet lines can remain constant or can be variable. Whenboth purge gas and reactive gases are flowing through the inlet linesentering the gas distribution plate, the purge gas serves to both form auniform pressure in the gas channel as well as dilute the concentrationof the reactive gas.

The pump line 40 can be used to evacuate the processing chamber and tohelp purge all gases from the inlet line 20 and purge gas line 30.Purging the gases from the gas delivery system using the pump line 40can be accomplished fruit use of bypass line 50. Bypass line valve 51can be opened so that there is fluid communication between the pump line40 and the inlet line 20. If the first inlet valve 25 and the secondinlet valve 26 are in the closed position, reactive gases flowingthrough inlet line 20 and inlet valve 24 will flow directly through thebypass valve 51 and bypass line 52 be pumped out of the system. Closinginlet valve 24 would ensure that no additional reactive gases lostdirectly to the pump line and allow for the complete evacuation of thesystem downstream of the inlet valve 24. Opening the first inlet valve25 and second inlet valve 26 while keeping inlet valve 24 closed willcause purge gas flowing from the first purge line 31 and the secondpurge line 32 to backflow through inlet valve 25 and inlet valve 26,past the white 23, and through bypass valve 51 of bypass line 52 thepump. This operation can ensure that the entire gas system has beenpurged of reactive gases downstream of inlet valve 24.

During processing, the reactive gas flowing through inlet line 20 can bechanged as often as is necessary. Changing the reactive gas can be usedfor atomic layer deposition type processing in which the substrate isalternately exposed to a precursor and a reactant to form a film on thesubstrate surface. A manifold (not shown) can be connected to the inletline 20 so that the reactive gas flowing into inlet line 20 can bechanged. The pump line 40 and combination of valves can be used toensure that the gas delivery system has been purged of a first reactivegas before allowing the second reactive gas to flow through system. Thishelps to ensure that there are no gas phase Reactions within the system.

In the embodiment shown in FIG. 2, both the first reactive gas, labeledas A, and the second reactive gas, labeled as B, can be flowed into theprocessing chamber at the same time. This is particularly useful wherethe gas distribution plate is able to maintain separation of the gasesuntil after they have been flowed into the processing chamber. Forexample, see the embodiments described with respect to FIGS. 10-17. Theembodiments shown has two purge inlet lines 30 a, 30 b. While theselines are shown as separate, it will be understood by those skilled inthe art, that both lines can come from the same gas source and be splitby any suitable splitting mechanism such as a gradient proportioningvalve.

The left side of FIG. 2, where the first reactive gas A is shown, has apurge line 50 positioned downstream of wye 23 and connects to both thefirst input line 21 a and the second input line 22 a. To split thebypass line 50 so that it can connect with both the first input line,wye 53 can be any suitable type of splitting mechanism such, but notlimited to, a gradient proportioning valve. The embodiment shown has thebypass line 50 connecting to the first input line and second input linedownstream of the first purge gas line 31 a and the second purge gasline 32 a. However, it will be understood by those skilled in the art,that this connection can occur upstream of the first purge gas line 31 aand second purge gas line 32 a, or a combination of upstream anddownstream. In embodiments such as this, it may be particularly usefulto have valves along the first purge gas line and the second purge gasline, as well as on any of the first input line, second input line andbypass line.

Referring to FIGS. 3 and 4, one or more embodiments are directed to gasdistribution apparatus 100 to deliver a gas to a process chamber (notshown). The gas distribution apparatus 100 comprises a delivery channel102 with a first end 104 and a second end 106. The delivery channel 102has a plurality of apertures 108 spaced along the length of the deliverychannel 102. An connector 110 is connected to and in fluid communicationwith the inlet end 104 of the delivery channel 102. A connector 112 isconnected to and in fluid communication with the second end 106 of thedelivery channel 102. The connector 110 is adapted to be connected to agas delivery system or gas source and may include a valve 114 capable ofcontrolling the flow of gas into (or out of) the delivery channel 102 orcompletely cut off the flow of gas. The connector 112 is adapted to beconnected to a gas delivery system and may include a valve 116 capableof controlling the flow of gas into (or out of) the delivery channel 102or completely cut off the flow of gas.

A controller 150 regulates the flow of the gas through the deliverychannel 102 and into the process chamber. The controller 150 does thisby opening or closing (or any point in between fully open and fullyclosed) the various valves during gas delivery and gas purging. Thiscontrols the flow of gas through apertures (seen, for example, in FIG.5) spaced along the length of the channel.

The cross-sectional shape of the delivery channel 102 can be controlledsuch that gas flowing through the delivery channel experiences minimalresistance to flow. In some embodiments, the delivery channel 102 has around or oval cross-sectional shape. In one or more embodiments, thedelivery channel 102 has a cross-sectional shape sufficient such thatbends, turns, twists, etc. provide substantially no dead space.

The overall shape (as opposed to the cross-sectional shape) of thedelivery channel 102 can be modified as desired. For example, thedelivery channel 102 can be shaped to fit within specific areas or tomatch the shape of a substrate. The delivery channel 102 can be, forexample, straight, round, square, oval, rectangular or oblong.Additionally, the overall shape of the delivery channel can be made upof repeating units, parallel, perpendicular or concentric to each other.In one or more embodiments, the delivery channel has an overall shape inwhich there is substantially no dead space to inhibit gas flow orpurging. As used in this specification and the appended claims, the term“substantially no dead space” means that the flow of gas, or purging, isinhibited by less than about 10% or by less than about 5% due to deadspace.

In some embodiments, the delivery channel 102 is a tubular spiral havinga substantially planar configuration. This particular shape isexemplified by the embodiment shown in FIGS. 3 and 4. As used in thisspecification and the appended claims, the term “substantially planarconfiguration” means that the plurality of apertures 108 in the deliverychannel 102 are in mostly the same plane. The embodiment shown in FIGS.3 and 4 has a substantially planar configuration because the aperturesare coplanar, even though the inlet end and outlet end, and the portionsof the delivery channel near the inlet end and outlet end are notcoplanar with the plurality of apertures.

The delivery channel 102 can be used for plasma processing. For example,the delivery channel 102 can be polarized relative to another portion ofthe processing chamber to ignite a plasma within the chamber. Thedelivery channel 102 can be biased relative to a portion of the chamber,or a portion of the chamber can be biased relative to the deliverychannel 102. For example, the delivery channel 102 can be polarizedrelative to a substrate support pedestal in a processing chamber, or thepedestal can be polarized relative to the delivery channel. Thefrequency of the plasma can be tuned as well. In one or moreembodiments, the plasma is at a frequency of about 13.56 MHz. In someembodiments, the plasma is at a frequency of about 40 MHz, 50 MHz, 60MHz, 70 MHz, 80 MHz, 90 MHz, 100 MHz, 110 MHz or 120 MHz.

Any suitable material can be used for the delivery channel, showerheador gas distribution apparatus. Suitable materials include, but are notlimited to stainless steel and inert materials. In some embodiments, thedelivery channel, showerhead or gas distribution plate is made ofstainless steel.

FIGS. 5 through 8 show another embodiment of a gas distributionapparatus 400 in which the delivery channel 402 is a recessed channel inthe back side 401 of a gas distribution plate 403. The embodiment shownhas a large inner section is recessed in the back side 401 of the gasdistribution plate 403 with the delivery channel 402 recessed evenfurther. This allows for the addition of a back cover 407 which can beplaced in the recessed area in the back side 401 enclosing the deliverychannel 402. The back cover 407, when inserted into the recessed backside 401 of certain embodiments creates a substantially flush back sidesurface of the gas distribution plate. It will be understood by thoseskilled in the art that the back cover 407 does not need to fit within arecessed area of the back side 401 of the gas distribution plate 403,but can also rest directly on the back side 401 of the gas distributionplate 403. In embodiments of this sort, there is no large recessed areawith the delivery channels being further recessed. Instead, the deliverychannels are recessed directly into the back side 401 of the gasdistribution plate 403.

The back cover 407 may have openings to allow for the passage of inletand outlet tubes to allow for fluid communication with the deliverychannel 402. For example, connectors 404, 406 can act as inlets oroutlets or both depending on the processing conditions. This can be seenin FIGS. 6 and 7. The inlet and outlet tubes can be an integral part ofthe back cover 407, or can be separate pieces connected to the backcover 407 in such a manner as to prevent or minimize fluid leakage. Aplurality of apertures 408 extend through the gas distribution plate 403to a front side 405 of the gas distribution plate 403. These aperturescan be seen in FIGS. 6, 7 and 8. The plurality of apertures 408 can beevenly spaced along the length of the delivery channel, or can havevaried spacing along the length of the channel. Variable spacing mayhelp produce a more uniform gas flow from the delivery channel at pointsalong the delivery channel. For example, in gas delivery channel thathas an elaborate shape, the spacing of the apertures can varied alongthe length.

In the embodiment shown in FIGS. 5-8, the gas distribution plate 403 isround and the delivery channel 402 forms a spiral shape. The connector404 is denoted at the outside of the spiral in an outer peripheralregion 420 of the gas distribution plate 403 with the connector 406 atthe center of the spiral in a central region 422 of the gas distributionplate 403. It will be understood by those skilled in the art that theconnector 404 and connector 406 can be inlets or outlets or both.

In FIGS. 6 and 7, connector 404 and connector 406 are illustrated as asmall tube extending from the back cover 407 of the gas distributionplate 403. The tubes extend between the inlet 410 and the back cover 407through an valve 414. Another tube can extend between the outlet 412 andthe back cover 407 through the valve 416. The tubes can be connected tothe back cover 407 by any suitable connection known to those skilled inthe art and may be sealed to prevent leakage of fluid flowing throughthe tube into the delivery channel 402. Suitable sealing devicesinclude, but are not limited to, o-rings positioned between a flange 424and the back cover 407. The flange 424 can be integrally formed with thetube or can be a separate piece that holds the tube to the back cover.The flange 424 can be connected to the back cover 407 by any suitablemechanical connection, including but not limited to, screws.

FIG. 9A shows a cross-sectional view of one portion of a deliverychannel 402 and an aperture 408 in a gas distribution plate 403 inaccordance with one or more embodiments of the invention. It will beunderstood by those skilled in the art that the delivery channel andapertures described in FIG. 9A are merely illustrative and should not betaken as limiting the scope of the invention. Those skilled in the artwill understand that there are other ways of creating flow from thedelivery channel 402 through the gas distribution plate 403. Thedelivery channel 402 shown in FIG. 9A has two portions, an upper portion832 and a lower portion 830. While these portions are shown as separateareas, it will be understood that there can be a seamless transitionbetween the upper portion 832 and the rounded lower portion 830.

Additionally, it will be understood that the upper portion 832 isoptional and does not need to be included in the delivery channel 402.When there is no upper portion 832, the lower portion 830 is the onlyportion. Thus, the delivery channel can have any suitable shape. In someembodiments, the shape of the delivery channel is such that there issubstantially no interference with the flow of gases through thechannel.

The upper portion 832 can have any suitable shape. In the embodimentshown in FIG. 9A, the upper portion 832 has walls which extend normal tothe surface of the back side 401 of the gas distribution plate 403.However, it will be understood that the upper portion 832 can have wallswhich are canted from square to the back side 401. The canting canprovide a larger opening at the back side 401 of the gas distributionplate 403, tapering to a smaller opening. Additionally, the canting canprovide a smaller opening at the back side 401, tapering to a largeropening. The length of the upper portion 832 can be modified asnecessary.

In some embodiments, the upper portion has sides which are substantiallyperpendicular to the back side 401 of the gas distribution plate 403 andextend a length L below the surface of the back side 401 in the range ofabout 0.01 inch to about 0.3 inches. As used in this specification andthe appended claims, the term “substantially perpendicular to” meansthat walls of the upper portion have an angle relative to the back sideof the gas distribution plate in the range of about 85 degrees to about95 degrees. In some embodiments, the upper portion extends below thesurface of the back side to a length L in the range of about 0.02 inchesto about 0.2 inches, or in the range of about 0.05 inches to about 0.15inches, or in the range of about 0.08 inches to about 0.12 inches. Inone or more embodiments, the upper portion extends below the surface ofthe back side to a length about 0.1 inches.

The rounded lower portion 830 can have any suitable cross-sectionincluding, but not limited to, half-round and half-elliptical. The widthof the rounded lower portion, also referred to as the diameter of therounded lower portion, can be modified as necessary. The width of theupper portion can be modified as necessary. The diameter of the deliverychannel, in general, can have an impact of the number of loops in thespiral. In some embodiments, as shown in FIG. 9A, the width of the upperportion is about equal to the diameter of the lower portion. Thedelivery channel of various embodiments has a diameter in the range ofabout 0.3 inches to about 0.45 inches, or in the range of about 0.325inches to about 0.425 inches, or in the range of about 0.35 inches toabout 0.40 inches. In one or more embodiments, the delivery channel hasa diameter of about 0.375 inches.

The specific shape of the apertures 408 can vary depending on thedesired flow of gases through the apertures. In the embodiment of FIG.9A, the aperture 408 has three distinct sections; a first section 834, asecond section 836 and a third section 838. Again, the number ofsections and the shape of the sections are merely illustrative of oneembodiment and should not be taken as limiting the scope of theinvention. The first section 834 extends from the rounded lower portion830 of the delivery channel 402 toward the front side 405 of the gasdistribution plate 403. The first section 834 has a first diameter D1.The second section 836 extends from the first section 834 toward thefront side 405 and has a diameter which tapers from the first diameterD1 to a second diameter D2, which is generally smaller than the firstdiameter. The third section 838 extends from the end of the secondsection 836 and ends at the front side 405 of the gas distribution plate403. At the intersection of the third section 838 and the front side405, a hole 840 is formed. Gases flowing through the delivery channel402 exit the gas distribution plate 403 through this hole 840 into theprocessing chamber. The hole 840 has about the same diameter as thesecond diameter D2. In various embodiments, the diameter of the hole 840is in the range of about 0.01 inches to about 0.25 inches, or in therange of about 0.02 inches to about 0.2 inches, or in the range of about0.03 inches to about 0.15 inches or in the range of about 0.04 inches toabout 0.1 inches. In some embodiments, the hold 840 has a diameter lessthan about 0.1 inches, or less than about 0.08 inches, or less thanabout 0.06 inches, or less than about 0.04 inches, or less than about0.02 inches, or less than about 0.01 inch.

As the delivery channel spirals from the outer peripheral edge of thegas distribution plate to the central region, or vice versa, a seemingplurality of adjacent channels are observable in cross-section, eventhough it may be a single channel. FIG. 6 shows this seeming pluralityof channels. The channels, or separation between loops of the spiral,are separated by a distance. In some embodiments, the distance betweenthe channels, or the loops of the single channel, measured from centers,are in the range of about 0.375 inches to about 0.475 inches, or in therange of about 0.40 inches to about 0.45 inches, or in the range ofabout 0.41 inches to about 0.43 inches. In one or more embodiments, theaverage distance between centers of the adjacent channels is about 0.42inches.

The length of the gas channel shown in FIGS. 5 to 8 can vary dependingon a number of factors, including, but not limited to, the diameter ofthe channel and the distance between the adjacent channels. In variousembodiments, the delivery channel has a length in the range of about 140inches to about 340 inches, or in the range of about 180 inches to about300 inches, or in the range of about 200 inches to about 280 inches, orin the range of about 220 inches to about 260 inches. In one or moreembodiments, the delivery channel has a length of about 240 inches.

The number of apertures are also dependent on a number of factors,including but not limited to, the length of the delivery channel and thespacing of the apertures. In some embodiments having a single spiralchannel, there are in the range of about 300 and 900 apertures, or inthe range of about 400 to about 800 apertures, or in the range of about500 to about 700 apertures. In various embodiments, there are greaterthan about 300, 400, 500, 600, 700 or 800 apertures along the length ofthe channel. In one or more embodiments, there are about 600 aperturesalong the length of the delivery channel.

In some embodiments, each of the plurality of apertures 403 has anindependent hole diameter and delivery angle relative to the front side405 of the gas distribution plate. The plurality of apertures 403 mayhave one or more of (1) variable spacing along the length of thedelivery channel; (2) variable hole diameters along the length of thedelivery channel; and (3) variable delivery angles along the length ofthe channel.

In some embodiments, the spacing between apertures vary depending on theexpected gas pressure in any particular region of the channel. Forexample, the gas pressure across the length of the channel will changedue to, for example, the presence of apertures allowing gas to escapethe channel. To counteract this pressure variability, there can be anincrease or decrease in the density of apertures. The regions of thechannel can be any length from the entire channel length to lengths lessthan the diameter of the apertures. For example, the first half of thechannel length can have apertures spaced a first amount and the nextquarter have apertures spaced closer together (i.e., a greater densityof apertures) with the last quarter being even greater density. In someembodiments, the spacing of the plurality of apertures decreases alongthe length of the delivery channel from the inlet end to the outlet end.The decreasing spaces can be between each channel or between blocks ofchannels.

The apertures can have any number of possible cross-sections. FIGS. 9Athrough 9G show a number of possible cross-sections. The apertures canbe a single straight line that leads from the channel to the front side,or can have a number of sections. The number of sections and shapes canhave an impact on the spray pattern of gases exiting the gas deliverychannel through the apertures. In some embodiments, the aperturescomprise a first section 834 having a first diameter and a secondsection 836 having a second diameter which is different from the firstdiameter. FIG. 9B shows an aperture 808 with a first section 834adjacent the gas delivery channel and extending toward the front side405. The second section 836 has a changing diameter which increases fromthe end closest the first section 834 toward the front side 405. Stateddifferently, the second diameter transitions from the first diameter tothe second diameter. A third section 838 connects the second section 836to the front side 405. The diameter of the third section 838 is thesecond diameter.

As shown in comparing FIGS. 9A and 9B, the first diameter can be largerthan or smaller than the second diameter. In FIG. 9A, the first diameteris larger than the second diameter and in FIG. 9B, the reverse is thecase.

FIGS. 9C and 9D show embodiments of the apertures which include a fourthsection 839. In FIG. 9C, the first section 834 has a first diameter, thesecond section 836 transitions from the first diameter to a seconddiameter, the third section extends from the second section 836 towardthe front side 405. A fourth section 839 extends from the third section838 to the front side 405 with a varying size diameter. The fourthsection 839 diameter increases from the second diameter to a thirddiameter at the front side 405 so that the hole 840 is larger than thesecond diameter. The third diameter can be the same as or different fromthe first diameter and is different from the second diameter. FIG. 9Dshows a similar situation in which the first diameter and seconddiameter are reversed. The size of the hole 840 and the angle of thefourth section 839 can vary and may impact the gas spray pattern. FIG.9E shows another embodiment in which there are two sections. The firstsection 834 extends from the gas delivery channel and has a firstdiameter. The second section 836 extends from the first section 834 tothe front side 405 and has a diameter starting at the first diameter andtransitioning gradually to the second diameter. While the seconddiameter shown is larger than the first diameter, it could also besmaller than the first diameter. The embodiments shown are merelyexemplary and should not be taken as limiting the scope of theinvention.

The width W of the gas delivery channels 402 and the pattern/number ofapertures 408 across the width W of the gas delivery channels can alsovary. FIG. 9F shows a cross-section of a portion of a gas distributionplate with two adjacent channels. The left channel has a width W muchlarger than the right channel. Additionally, the left channel has threeseparate apertures 408 extending in a line across the width of thechannel. Stated differently, there are three apertures in the channel atthe same distance from the inlet end. This means that the plurality ofapertures extend along the length of the channel and may also extendalong the wide of the channel. The two channels shown in FIG. 9F can beseparate portions of the same channel (e.g., adjacent channels of aspiral shape). The diameter of the channel can increase or decreasealong the length of the channel to change the gas flow pattern throughthe channel. The two channels shown in FIG. 9F can also be from separatechannels with different gases flowing therethrough. For example, the gasflowing through the wider left channel may not be as reactive as the gasflowing through the narrower right channel, and the amount of the leftgas exiting the channel is greater than the amount of the right gas.Again, these are merely examples of possible arrangements and should notbe taken as limiting the scope of the invention. The gas distributionapparatus of claim 1, wherein some of the plurality of aperturescomprise a plurality of passages forming a line extending across a widthof the delivery channel.

In some embodiments, the individual apertures extend toward the frontside 405 at varying angles from the gas delivery channel. The aperturescan also have variable delivery angles relative to the front side of thegas distribution plate. FIG. 9G shows an embodiment of the invention inwhich there are two adjacent channels with three apertures extendingacross the width of each. The channels can be delivering the same gas oradjacent channels delivering different gases. Of the three channels, oneextends straight down from the channel to make an angle about 90°, theside channels extend at an angle and make an angle Θ relative to thefront side of the gas distribution plate. The angle can be any suitableangle in the range of about 10° to about 90°. In one or moreembodiments, the angle is in the range of about 20° to about 85°, or inthe range of about 30° to about 80°, or in the range of about 40° toabout 75°. In some embodiments, as can be extrapolated from the channelsof FIG. 9G, at least some of the plurality of apertures have deliveryangles that direct a flow of gas toward a region under an adjacentdelivery channel. This can help with uniformity of the deposition byminimizing striping caused by shape of the channel.

In an embodiment, as shown in FIG. 5, the gas delivery plate 403comprises a single delivery channel 402 in a back side of the gasdelivery plate 403. The delivery channel 402 has ends 404, 406 locatedin an outer peripheral region and in a central region 422 of the gasdistribution plate 403. The delivery channel 402 has an overall length,defined as the distance between the first end 404 and the second end 406of about 240 inches. A plurality of apertures 408 are spaced along theoverall length of the delivery channel 402. Along the overall length ofthe delivery channel 403 there are in the range of about 500 aperturesand about 700 apertures. The delivery channel 403 has an averagediameter of about 0.375 inches and adjacent portions of the spiralchannel are spaced about 0.42 inches on center.

Some embodiments of the invention include more than one delivery channel402. These multiple channels can be intertwined or separate depending onthe needs of the processing system. Some channels can be recessed into agas distribution plate as shown in FIG. 5, or can be individual tubes asshown in FIG. 3. In some embodiments, there are a combination ofindividual tubes and recessed channels.

Another embodiment of the invention is shown in FIGS. 10 through 15. Agas distribution apparatus 900 comprises two delivery channels 902 a,902 b recessed in the back side 901 of a gas distribution plate 903. Itwill be understood that the delivery channels do not need to be recessedinto the back of a gas distribution plate, but can be individual tubes,as shown in FIGS. 3 and 16. The first delivery channel 902 a has a firstend 904 a and a second end 906 a and a plurality of first apertures 908a spaced along the length of the first delivery channel 902 a. Thesecond delivery channel 902 b has a third end 904 b, a fourth end 906 band a plurality of second apertures 908 b spaced along the length of thesecond delivery channel 902 b.

A connector 910 a is connected to the first end 904 a of the firstdelivery channel 902 a. The connector 910 a is adapted to be connectedto a gas source or a gas delivery system. A connector 912 a is connectedto the second end 906 a of the first delivery channel 902 a. Theconnector 912 a is adapted to be connected to a gas delivery system. Aconnector 910 b is connected to the third end 904 b of the seconddelivery channel 902 b. The connector 910 b is adapted to be connectedto a gas source or gas delivery system. A connector 912 b is connectedto the fourth end 906 b of the second delivery channel 902 b. Theconnector 912 a is adapted to be connected to a gas delivery system.

In the embodiment shown in FIGS. 10 to 15, each of the delivery channels902 a, 902 b form a spiral shape. One or more embodiments, as that shownin the Figures, have the two delivery channels 902 a, 902 b intertwinedalong the length of the spiral shape. It will be understood by thoseskilled in the art that the two delivery channels 902 a, 902 b can haveshapes other than spiral and do not need to intertwine. In certainembodiments, the plurality of first apertures 908 a and second apertures908 b extend through the gas distribution plate 903 to the front side905 of the gas distribution plate 903.

In some embodiments, each of the delivery channels 902 a, 902 b form aspiral shape with one or more of the first end 904 a, second end 906 a,third end 904 b and fourth end 906 b positioned in an outer peripheralregion 920 of the gas distribution plate 903 and one or more positionedin a central region 922 of the gas distribution plate 903. FIG. 11Ashows a cross-sectional view of a gas distribution plate with two gasdelivery channels. The shape, number, spacing and angles of theapertures can vary, as previously described. FIG. 11B shows a portion ofan embodiment of a gas distribution plate with a first delivery channel902 a and a second delivery channel 902 b. Both of these channels 902 a,902 b, at least at the cross-section shown, have two apertures extendingfrom the channel to the front side 905 of the gas distribution plate.The apertures shown are positioned at the outer edges of the channels sothat the gases in the channels are very close to each other when exitingthe apertures. The apertures between the first channel and the secondchannel can also be offset so that only one channel would have aperturesvisible in any given cross-section to prevent gas phase reactions.

FIG. 11C shows another embodiment in which there are two gas channelswith each channel having two apertures extending therefrom to form adelivery angle at the front side 905. Here, neither channel is shownwith an aperture that expels gas directly below that aperture, butinstead directs gases to the region beneath an adjacent channel. Thefirst delivery channel 902 a has an aperture that directs gas beneaththe second delivery channel 902 b and the second delivery channel 902 bhas an aperture that directs gas beneath the first delivery channel 902a. These apertures are shown to form holes at the same point on thefront side, but it will be understood that these can be staggered alongthe length of the channel or that the cross-section shown for eachchannel can be from a different length from the inlets.

The embodiment of FIG. 11C may be particularly effective at preventingdeposition striping from the placement and orientation of the gases.FIG. 11D shows the surface of a portion of a gas distribution plate inwhich the channels have apertures like that of FIG. 11C which haveoffset cross-sections. The pattern of holes on the front side 905presents an approximately alternating pattern of holes.

FIG. 12 shows a back cover 907 for the gas distribution plate 903 shownin FIG. 10. There are four holes (not numbered) located in the backcover 907 which align approximately with ends the delivery channels 902a, 902 b. The holes can be used to provide an access point forconnectors. In some embodiments, any or all of connectors 910 a, 910 b,912 a and 912 b are integrally formed with the back cover 907.Additionally, as seen in FIGS. 13 and 14, there can be one or morevalves 914 a, 914 b, 916 a, 916 b in flow communication with therespective gas lines.

FIGS. 13 and 14 show perspective views of a gas distribution apparatus900 in accordance with various embodiments of the invention. Theconnectors 910 a, 910 b are shown connected to the back cover 907 with aflange 924 a, 924 b. The connection and gas-tight sealing of the flange924 a, 924 b can be accomplished by any suitable mechanism andtechniques as known to those skilled in the art. The connectors 912 a,912 b can also be connected to the back cover 907 with a flange or witha block connection 925. The block 925 can be integrally formed with theback cover 907 or can be a separate piece. The block 925 may provideadditional support and space for the outlet valves 916 a, 916 b,allowing the connecting tubes to protrude from the back cover 907 at anangle.

As the delivery channels spiral from the outer peripheral edge of thegas distribution plate to the central region, or vice versa, a seemingplurality of adjacent channels are observable in cross-section. With thespirals intertwined, the gas in every adjacent channel is from the otherinlet 910 a, 910 b. The channels are separated by a distance from theadjacent channels. In some embodiments, the distance between thechannels, measured from the center of the channel, are in the range ofabout 0.375 inches to about 0.475 inches, or in the range of about 0.40inches to about 0.45 inches, or in the range of about 0.41 inches toabout 0.43 inches. In one or more embodiments, the average distancebetween centers of the adjacent channels is about 0.42 inches.

The length of the gas channel shown in FIGS. 10-15 can vary depending ona number of factors, including, but not limited to, the diameter of thechannel and the distance between the adjacent channels. In variousembodiments, each of the delivery channels has a length in the range ofabout 70 inches to about 170 inches, or in the range of about 90 inchesto about 150 inches, or in the range of about 100 inches to about 140inches, or in the range of about 110 inches to about 130 inches. In oneor more embodiments, the delivery channel has a length of about 120inches.

The number of apertures are also dependent on a number of factors,including but not limited to, the length of the delivery channel and thespacing of the apertures. In some embodiments having a single spiralchannel, there are in the range of about 150 and 450 apertures, or inthe range of about 200 to about 400 apertures, or in the range of about250 to about 350 apertures. In various embodiments, there are greaterthan about 150, 200, 250, 300, 350 or 400 apertures along the length ofthe channel. In one or more embodiments, there are about 300 aperturesalong the length of each of the delivery channels.

In some embodiments of the apparatus exemplified by FIGS. 5 through 15,there is an insulating material (not shown) positioned between the backcover and the main body portion of the gas distribution apparatus (i.e.,the portion including the gas delivery channel). This insulatingmaterial provides electrical isolation between the back cover and themain body portion of the gas distribution apparatus so that the backcover can be polarized relative to the main body portion. Doing so mayallow for the ignition of a plasma within the gas distributionapparatus, or within the delivery channels. The plasma can then beflowed through the plurality of apertures into the processing region ofthe processing chamber, the processing region being the region betweenthe gas distribution apparatus and the pedestal. This configuration maybe referred to as a remote plasma because the plasma is formed (e.g.,ignited) outside of the processing region.

FIGS. 16 and 17 show another exemplary embodiment of a gas distributionapparatus 1500. The gas distribution apparatuses shown are particularlyuseful for spatially separated atomic layer deposition processes inwhich different portions of the substrate are simultaneously exposed todifferent deposition gases and the substrate 1544 is moved relative tothe gas distribution apparatus so that all parts of the substrate areexposed sequentially to each of the deposition gases. In theseembodiments, the gas distribution apparatus 1500 comprises a pluralityof delivery channels 1502, each delivery channel 1502 extendingsubstantially straight and substantially parallel to adjacent deliverychannels. Each of the delivery channels 1502 has a first end 1504 and asecond end 1506 with a plurality of spaced apertures 1508 there between.A gas distribution system can be in flow communication with any or bothof the first end and the second end.

The gas distribution apparatus shown in FIGS. 16 and 17 have a pluralityof elongate delivery channels 1502 and a plurality of elongate vacuumchannels 1550. Each of the delivery channels 1502 and vacuum channels1550 are connected to a output channel 1552 at the front side of the gasdistribution apparatus. Each of the delivery channels 1502 is adapted toflow one or more of a reactive gas and a purge gas. Each deliverychannel 1502 is connected to an output channel 1552 by a plurality ofspaced apertures 1508. Each of the vacuum channels 1550 is connected toan inlet channel 1554 by a plurality of spaced vacuum apertures 1558.The plurality of apertures 1508 of each delivery channel 1502 areseparated from the plurality of apertures 1508 of each adjacent deliverychannel 1502 by at least one plurality of vacuum apertures 1558 from avacuum channel 1550.

In the embodiment shown in FIG. 17, each of the central vacuum channels1550 (not the end vacuum channels) are connected to two inlet channels1554 by vacuum apertures 1508. The end vacuum channels 1550 are onlyconnected to a single inlet channel 1554. It should be understood thatthis is merely exemplary and should not be taken as limiting the scopeof the invention. Each inlet channel 1554 can have a dedicated vacuumchannel 1550, or a single vacuum channel 1550 can be connected to morethan two inlet channels 1554 through a plurality of vacuum apertures1508.

While each of the delivery channels appear the same, there can be adifferent gas flowing through each. For example, purge channels (denotedP) may have a purge gas flowing there through, each of the firstreactive gas channels (denoted A) may have a first reactive gas flowingthere through and each of the second reactive gas channels (denoted B)may have a second reactive gas flowing there through. The vacuumchannels (denoted V) are connected to a vacuum source. With reference toFIG. 17, a substrate 1544 (or more specifically, a fixed point on asubstrate) moving from left to right would encounter in order a vacuumgas channel, a purge gas channel, a vacuum gas channel, a first reactivegas channel, a vacuum gas channel, a purge gas channel, a vacuum gaschannel, a second reactive gas channel, a vacuum gas channel, etc.,depending on the size of the gas distribution plate.

The delivery channel of FIGS. 16 and 17 can be used for plasmaprocessing as well. The gas distribution apparatus 1500 can be biasedrelative to another portion of the chamber. For example, the gasdistribution apparatus 1500 can be polarized relative to the pedestal,or the pedestal can be polarized relative to the gas distributionapparatus. The frequency of the plasma can be tuned as well. In one ormore embodiments, the plasma is at a frequency of about 13.56 MHz. Insome embodiments, the plasma is at a frequency of about 40 MHz, 50 MHz,60 MHz, 70 MHz, 80 MHz, 90 MHz, 100 MHz, 110 MHz or 120 MHz.

In one or more embodiments, the gas distribution apparatus includes morethan one outlet connected to a vacuum source. FIG. 18 shows a spiralshaped gas distribution apparatus 1700 which is similar to the apparatus100 shown in FIG. 3. The apparatus includes a delivery channel 1702 witha first end 1704 and a second end 1706. An connector 1710 is connectedto and in communication with the first end 1704 of the delivery channel1702. A connector 1712 is connected to and in communication with thesecond end 1706 of the delivery channel 1702. The connector 1710 isconnectable to a gas source (or vacuum source) and may include a valve1714 that can control the flow of gas into (or out of) the deliverychannel 1702 or completely cut off the flow of gas. An intermediateconnector 1742, which is connectable to the gas delivery system, isposition along the length of the delivery channel 1702. The intermediateconnector 1742 shown is connected to the delivery channel 1702 at aboutthe middle of the length of the channel 1702 and coupled to the deliverychannel 1702 through an intermediate port 1740. The intermediateconnector 1742 may include an intermediate valve 1744 that can controlthe flow of gas out of (or into) the delivery channel 1702 or completelycut off the gas flow. The valve 1714, 1716, 1744 are connected to acontroller 1750. The controller is capable of independently opening orclosing any or all of the valves to adjust the pressure of gases flowingthrough the delivery channel 1702 or purge the delivery channel 1702 ofan existing gas.

The embodiment shown in FIG. 18 effectively includes two ends and oneintermediate connector. Those skilled in the art will understand thatthere can be any number of connectors and/or ports spaced along thelength of the delivery channel and at any position along the length ofthe channel. For example, the intermediate connector 1740 could bepositioned at ⅓ of the length of the channel. Additionally, there can beany number of connectors. For example, the delivery channel may havefour connectors, one at the end and one positioned at each of ¼, ½ and ¾of the length of the delivery channel. In another example, the deliverychannel includes four connectors, one at the end and one position ateach of ¼, ¾ and 9/10 of the length of the delivery channel. In someembodiments, the delivery channel includes 2, 3, 4, 5, 6, 7, 8, 9, 10 or11 total connectors (including a first end and a second end connector).

FIG. 19A shows the front surface 1912 of a showerhead 1911 in accordancewith one or more embodiment of the invention. The showerhead 1911 isdivided into a plurality of sections 1915. FIG. 19A shows a showerhead1911 divided into four sections, each taking about one-fourth of theshowerhead 1911. This is merely exemplary, and as shown in otherembodiments, the showerhead 1911 can be divided into any number ofsections having about equal area. Each of the four sections shown inFIG. 19B has about equal areas. As used in this specification and theappended claims, the term “equal area”, and the like, mean that each ofthe areas of the first surface attributed to the sections are withinabout 5% of each other.

Each of the plurality of sections 1915 comprises a gas delivery channel1920. While FIG. 19A only shows one gas delivery channel 1920 in theupper right section, it will be understood that this is merely forillustrative purposes and that gas delivery channels 1920 will belocated in each of the sections 1915. FIG. 19B shows an expanded view ofthe gas delivery channel 1920 shown in FIG. 19A. The gas deliverychannels 1920 extend through the body 1913 of the showerhead 1911. Thegas delivery channel 1920 includes a first end 1921 and a second end1922. The first end 1921 and second end 1922 are in fluid communicationwith a gas delivery system like that shown in FIGS. 1 and 2.

Many factors can affect the flow of gas through the gas delivery channel1920. For example, the shape of the channel including the number andangle of turns. Without being bound by any particular theory ofoperation, it is believed that the more bends there are in the channel,the greater the pressure drop across the channel (lengthwise). This isbelieved to be true for the angle of the turns as well.

In one or more embodiments, the gas delivery channel 1920 in eachsection comprises a series of connected L-shaped portions. This can beseen in the embodiment of FIG. 19B. Each of the L-shaped portions shownin FIG. 19B have about equal length legs 1941 for each equivalent row.For example, the channel row closes to the center of the showerhead hasabout equal length legs. Although it will be understood by those skilledin the art that there will be variability in the length of the legs andthat this should not be taken as limiting the scope of the invention.For example, the left-most leg 1941 shown is slightly longer than thebottom-most leg because the left-most leg connects to the inlet 1921.The size of the L-shaped portions decreases as each portion movesfurther from the center 1918 of the showerhead 1911 toward an outerportion 1919 of the showerhead.

In some embodiments, as shown in FIG. 20, the flow channels in eachsection are rotationally symmetrical to the other flow channels. As usedin this specification and the appended claims, the term “rotationallysymmetrical” means that when looking at the first surface, turning theshowerhead by 1/nth will result in a rotationally symmetricalshowerhead, where n is the number of sections 1915. For example,rotating the section shown in the upper right quadrant about the center1918 would result in a four-fold symmetrical pattern. The arrows shownin FIGS. 20 and 21 indicate that the gas delivery system is providing aflow of gas through each end of each gas delivery channel.

The aperture patterns shown in FIGS. 20 and 21 a sufficient for twoseparate gases. For example, a precursor gas and a reactant gas can beflowed through the showerhead simultaneously so that they are isolatedfrom each other until entering the processing chamber. In this case,each of the channel ends associated with the gas delivery channel forthe precursor can be referred to as the first end or second end.Assuming that the valves shown in FIGS. 20 and 21 are connected to thesame gas channel, each of the light valves can be connected to the firstend and each of the dark valves can be connected to the second end (orvice versa). This means that there are four first ends and four secondends shown in FIG. 20 and two first ends and four second ends in FIG.21. It will be appreciated that each of these are equivalent gasdelivery channels and that the gas channels associated with the reactantgas will have third ends and fourth ends, which are named as such merelyto indicate that they are different flow channels.

In some embodiments, as shown in FIG. 21, the gas delivery channel 1920in each section 1915 are mirror images of the adjacent sections 1915. Asused in this specification and the appended claims, the term “mirrorimages” means that if a first section were flipped about one radial axisto form a second section, the flow channel design of the first sectionwould form a mirror image of the second section. This does not meantthat the direction of the passages and the first surface change, itmerely refers to the design, or shape, of the flow channel and thelocation of the inlet and outlet. For example, FIG. 21 shows anembodiment where the sections are mirror images. It can also be seenfrom FIG. 21, that two adjacent sections 1915 can share a common end1923 with separate ends 1924 on the other side of the gas deliverychannel.

The gas distribution apparatus described can be used to form one or morelayers during a plasma enhanced atomic layer deposition (PEALD) process.In some processes, the use of plasma provides sufficient energy topromote a species into the excited state where surface reactions becomefavorable and likely. Introducing the plasma into the process can becontinuous or pulsed. In some embodiments, sequential pulses ofprecursors (or reactive gases) and plasma are used to process a layer.In some embodiments, the reagents may be ionized either locally (i.e.,within the processing area) or remotely (i.e., outside the processingarea). Remote ionization can occur upstream of the deposition chambersuch that ions or other energetic or light emitting species are not indirect contact with the depositing film. In some PEALD processes, theplasma is generated external from the processing chamber, such as by aremote plasma generator system. The plasma may be generated via anysuitable plasma generation process or technique known to those skilledin the art. For example, plasma may be generated by one or more of amicrowave (MW) frequency generator or a radio frequency (RF) generator.The frequency of the plasma may be tuned depending on the specificreactive species being used. Suitable frequencies include, but are notlimited to, 2 MHz, 13.56 MHz, 40 MHz, 60 MHz and 100 MHz. Althoughplasmas may be used during the deposition processes disclosed herein, itshould be noted that plasmas may not be required.

According to one or more embodiments, the gas distribution apparatus canbe used to subject a substrate to processing prior to and/or afterforming the layer. This processing can be performed in the same chamberor in one or more separate processing chambers. In some embodiments, thesubstrate is moved from the first chamber to a separate, second chamberfor further processing. The substrate can be moved directly from thefirst chamber to the separate processing chamber, or it can be movedfrom the first chamber to one or more transfer chambers, and then movedto the desired separate processing chamber. Accordingly, the processingapparatus may comprise multiple chambers in communication with atransfer station. An apparatus of this sort may be referred to as a“cluster tool” or “clustered system”, and the like.

Generally, a cluster tool is a modular system comprising multiplechambers which perform various functions including substratecenter-finding and orientation, degassing, annealing, deposition and/oretching. According to one or more embodiments, a cluster tool includesat least a first chamber and a central transfer chamber. The centraltransfer chamber may house a robot that can shuttle substrates betweenand among processing chambers and load lock chambers. The transferchamber is typically maintained at a vacuum condition and provides anintermediate stage for shuttling substrates from one chamber to anotherand/or to a load lock chamber positioned at a front end of the clustertool. Two well-known cluster tools which may be adapted for the presentinvention are the Centura® and the Endura®, both available from AppliedMaterials, Inc., of Santa Clara, Calif. The details of one suchstaged-vacuum substrate processing apparatus is disclosed in U.S. Pat.No. 5,186,718, entitled “Staged-Vacuum Wafer Processing Apparatus andMethod,” Tepman et al., issued on Feb. 16, 1993. However, the exactarrangement and combination of chambers may be altered for purposes ofperforming specific steps of a process as described herein. Otherprocessing chambers which may be used include, but are not limited to,cyclical layer deposition (CLD), atomic layer deposition (ALD), chemicalvapor deposition (CVD), physical vapor deposition (PVD), etch,pre-clean, chemical clean, thermal treatment such as RTP, plasmanitridation, degas, orientation, hydroxylation and other substrateprocesses. By carrying out processes in a chamber on a cluster tool,surface contamination of the substrate with atmospheric impurities canbe avoided without oxidation prior to depositing a subsequent film.

According to one or more embodiments, the substrate is continuouslyunder vacuum or “load lock” conditions, and is not exposed to ambientair when being moved from one chamber to the next. The transfer chambersare thus under vacuum and are “pumped down” under vacuum pressure. Inertgases may be present in the processing chambers or the transferchambers. In some embodiments, an inert gas is used as a purge gas toremove some or all of the reactants after forming the silicon layer onthe surface of the substrate. According to one or more embodiments, apurge gas is injected at the exit of the deposition chamber to preventreactants from moving from the deposition chamber to the transferchamber and/or additional processing chamber. Thus, the flow of inertgas forms a curtain at the exit of the chamber.

A substrate can be processed in single substrate deposition chambersusing, for example, the gas distribution apparatus described. In suchchambers, a single substrate is loaded, processed and unloaded beforeanother substrate is processed. A substrate can also be processed in acontinuous manner, like a conveyer system, in which multiple substrateare individually loaded into a first part of the chamber, move throughthe chamber and are unloaded from a second part of the chamber. Theshape of the chamber and associated conveyer system can form a straightpath or curved path. Additionally, the processing chamber may be acarousel in which multiple substrates are moved about a central axis andare exposed to deposition, etch, annealing, cleaning, etc. processesthroughout the carousel path.

During processing, the substrate can be heated or cooled. Such heatingor cooling can be accomplished by any suitable means including, but notlimited to, changing the temperature of the substrate support andflowing heated or cooled gases to the substrate surface. In someembodiments, the substrate support includes a heater/cooler which can becontrolled to change the substrate temperature conductively. In one ormore embodiments, the gases (either reactive gases or inert gases) beingemployed are heated or cooled to locally change the substratetemperature. In some embodiments, a heater/cooler is positioned withinthe chamber adjacent the substrate surface to convectively change thesubstrate temperature.

The substrate can also be stationary or rotated during processing. Arotating substrate can be rotated continuously or in discreet steps. Forexample, a substrate may be rotated throughout the entire process, orthe substrate can be rotated by a small amount between exposure todifferent reactive or purge gases. Rotating the substrate duringprocessing (either continuously or in steps) may help produce a moreuniform deposition or etch by minimizing the effect of, for example,local variability in gas flow geometries.

Although the invention herein has been described with reference toparticular embodiments, it is to be understood that these embodimentsare merely illustrative of the principles and applications of thepresent invention. It will be apparent to those skilled in the art thatvarious modifications and variations can be made to the method andapparatus of the present invention without departing from the spirit andscope of the invention. Thus, it is intended that the present inventioninclude modifications and variations that are within the scope of theappended claims and their equivalents.

The invention claimed is:
 1. A gas distribution apparatus to control aflow of gas into a process chamber, comprising: a gas distribution platehaving a front side and a back side; a gas delivery channel extendingthrough the gas distribution plate, the delivery channel having a lengthdefined by a first end and a second end, the delivery channel includinga plurality of apertures spaced along the length extending through thegas distribution plate to the front side of the gas distribution plate;a gas delivery system connected to the first end and the second end ofthe delivery channel, the gas delivery system comprising a first inletline in flow communication with the first end of the delivery channeland the second inlet line in flow communication with the second end ofthe delivery channel, a pump line, a first purge line in flowcommunication with the first inlet line and a second purge line in flowcommunication with the second inlet line; and a controller to regulatethe flow of the gas through the delivery channel and into the processchamber.
 2. The gas distribution apparatus of claim 1, furthercomprising an inlet line in flow communication with the first inlet lineand the second inlet line and an inlet wye which separates gas flowingthrough the inlet line into the first inlet line and second inlet line.3. The gas distribution apparatus of claim 2, further comprising aninlet valve in flow communication with the inlet line upstream of theinlet wye.
 4. The gas distribution apparatus of claim 2, furthercomprising a first inlet valve in flow communication with the firstinlet line and a second inlet valve in flow communication with thesecond inlet line.
 5. The gas distribution apparatus of claim 1, furthercomprising a purge line in flow communication with the first purge lineand the second purge line and a purge wye to separate gas flowingthrough the purge line into the first inlet line and second inlet line.6. The gas distribution apparatus of claim 5, wherein further comprisinga purge valve in flow communication with the purge line upstream of thepurge wye.
 7. The gas distribution apparatus of claim 5, furthercomprising a first purge valve in flow communication with the firstpurge line and a second purge valve in flow communication with thesecond purge line.
 8. The gas distribution apparatus of claim 1, whereinthe pump line is in flow communication with the first inlet line and thesecond inlet line.
 9. The gas distribution apparatus of claim 8, furthercomprising a pump valve in flow communication with the pump line. 10.The gas distribution apparatus of claim 1, wherein the purge linemaintains a constant flow of a purge gas.
 11. The gas distributionapparatus of claim 1, further comprising a bypass line in flowcommunication with the inlet line and the pump line.
 12. A gasdistribution apparatus to control a flow of gas into a process chamber,comprising: a gas distribution plate having a front side and a backside; a first gas delivery channel extending through the gasdistribution plate, the first delivery channel having a length definedby a first end and a second end, the first delivery channel including aplurality of apertures spaced along the length extending through the gasdistribution plate to the front side of the gas distribution plate; asecond gas delivery channel extending through the gas distributionplate, the second delivery channel having a length defined by a thirdend and a fourth end, the second delivery channel including a pluralityof apertures spaced along the length extending through the gasdistribution plate to the front side of the gas distribution plate; agas delivery system comprising a first inlet line, a second inlet line,a third inlet line, a fourth inlet line, a pump line, a first purgeline, a second purge line, a third purge line and a fourth purge line,the first inlet line in flow communication with the first end of thefirst gas delivery channel, the second inlet line in flow communicationwith the second end of the first gas delivery channel, the third inletline in flow communication with the third end of the second gas deliverychannel and the fourth inlet line in flow communication with the fourthend of the second gas delivery channel, the first purge line in flowcommunication with the first inlet line, the second purge line in flowcommunication with the second inlet line, the third purge line in flowcommunication with the third inlet line and the fourth purge line inflow communication with the fourth inlet line; and a controller toregulate the flow of the gas through the first gas delivery channel andthe second gas delivery channel and into the process chamber.
 13. Thegas distribution apparatus of claim 12, wherein the first gas deliverychannel and the second gas delivery channel are intertwined spirals. 14.The gas distribution apparatus of claim 12, wherein the first gasdelivery channel is positioned above the second gas delivery channel.15. The gas distribution apparatus of claim 1, wherein the purge linemaintains a constant flow of a purge gas.
 16. The gas distributionapparatus of claim 1, further comprising a bypass line in flowcommunication with one or more of the first inlet line and the secondinlet line and the pump line, and a second bypass line in flowcommunication with one or more of the third inlet line and the fourthinlet line and with the pump line.
 17. A processing chamber comprisingat least one gas distribution apparatus according to claim
 12. 18. Theprocessing chamber of claim 17, wherein the gas distribution apparatuscomprises at least two first gas delivery channels and at least twosecond gas delivery channels, each of the first gas delivery channelsand second gas delivery channels arranged to form a circular gasdistribution assembly.